Multilayer coated multicolor yarn and manufacturing method thereof

ABSTRACT

The multilayer coated multicolor yarn according to the present invention is part-colored and exposes various colors on the surface of the yarn, and, therefore, a fabric woven by the inventive yarn gives a unique aesthetic feeling. In addition, due to the multiple urethane coating layers, the yarn has excellent abrasion resistance, mechanical properties, durability, thermoformability and adhesion property.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to Korean patent application10-2016-0069055, filed on Jun. 2, 2017, incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to a coated yarn, and more particularly,to a parti-colored yarn having multiple layers of urethane coating forimparting strength and multicolor to a yarn by exposing each color ofeach layer on the surface of the yarn, and a method of manufacturingsame.

BACKGROUND OF THE INVENTION

Generally, an industrial yarn is produced by coating a thermoplasticresin such as PVC, PP, or thermoplastic polyurethane (TPU) on thesurface of a polyester or nylon yarn using an extruder die in order toincrease the strength of yarn.

However, it is hard to coating a small amount of coating resin, and,therefore, it is difficult to fabricate a coated yarn having a thicknessof 1,000 denier or less. Otherwise, it is difficult to improve thedurability and abrasion resistance of a coated yarn.

To solve such problem, Korean Patent No. 10-1318135 discloses athermoplastic polyurethane compound composition for producing a coatedyarn, which comprises thermoplastic polyurethane, a thickener and anolefin-based coupling agent.

Further, Korean Patent No. 10-1341055 entitled “A composition ofthermoplastic polyurethane yarn and a method for producing same”describes a method for producing a multi-layered thermoplasticpolyurethane yarn comprising the steps of mixing thermoplasticpolyurethane, a thickener and a processing lubricant; melting andkneading the mixture; drying and aging to prepare a resin compound; andintroducing the resin compound into a co-extruder to form a core yarnwhile introducing another resin selected from thermoplasticpolyurethane, polyester, nylon and acryl into the co-extruder to form ashell layer.

However, although a coated yarn having a relatively thin coating layercan be produced by the above-mentioned methods, it is hard to realize alight weight since the density of the coated yarn is high. Further, itis difficult to implement a coated yarn having various colors, texturesand functionalities, e.g., metallic feeling, thermochromic property,phosphorescent property, shifting colors, etc.

Hence, Korean Patent No. 10-1561890 filed and owned by the applicantprovides an aqueous thermosetting urethane composition for coating yarnscapable of realizing multi-layered yarn having a low density, i.e.,light weight and improved physical properties including elasticity andtextures.

DISCLOSURE OF INVENTION Technical Problem

It is an object of the present invention to provide a multilayeredmulticolor yarn which can embody various colors in a single yarn.

It is another object of the present invention to provide a method forproducing the multilayered multicolor yarn.

Solution to Problem

In a first aspect, the subject invention provides a multilayer coatedmulticolor yarn comprising a core yarn, a first coating layer formed onthe core yarn and a second coating layer formed on the first coatinglayer, wherein at least a part of the first coating layer is not coveredby the second coating layer so that each colors of the first and secondcoating layers appear at the surface of the multilayer coated multicoloryarn.

In another aspect, the multilayer coated multicolor yarn may furthercomprise a third coating layer formed on the second coating layer,wherein at least a part of the second coating layer is not covered bythe third coating layer and at least a part of the first coating layernot covered by the second coating layer is not covered by the thirdcoating layer so that each colors of the first, the second and thirdcoating layers appear at the surface of the multilayer coated multicoloryarn.

In a further aspect, the multilayer coated multicolor yarn may furthercomprise an additional coating layer on the third coating layer, whereineach color of each coating layer appears at the surface of themultilayer coated multicolor yarn.

In an additional aspect, the multilayer coated multicolor yarn may be atwisted yarn twisted with a rotational speed of 1,000 to 10,000 rpm.

In an additional aspect, the multilayer coated multicolor yarn may byprepared by a method comprising the steps of coating a first resincomposition including a first pigment on the surface of a core yarn anddrying the first resin composition to form a first coating layer on thecore yarn; coating a second resin composition including a second pigmenton the first coating layer to form a second coating layer; removing apart of the second coating layer so that the first coating layer ispartially exposed to the outside; and drying the second coating layer.

In an additional aspect, the method for preparing a multilayer coatedmulticolor yarn may further comprise the steps of coating a third resincomposition including a third pigment after drying the second coatinglayer to form a third coating layer; removing a part of the thirdcoating layer so that the first and second coating layers are partiallyexposed to the outside; and drying the third coating layer.

In an additional aspect, a part of the second coating layer or the thirdcoating layer may be removed by scraping a part of the second or thirdcoating layer before drying.

In an additional aspect, a part of the coating layer may be scraped bymaking a coated yarn discharging from an outlet of a coater contact withan edge of the outlet at a predetermined discharge angle by using aroller.

In an additional aspect, the roller may be an eccentric roller and thecoated yarn contacts with the edge of the coater outlet at differentpoints.

In an additional aspect, the roller may be mounted on a rotatable meanswhich rotates at 360 degrees with respect to the center axis of thecoater outlet so that the coated yarn discharge from the coater outletmay contact with the circumference of the outlet edge.

In an additional aspect, the method may further comprise twistingfinally dried coated yarn to obtain twisted yarn.

Advantageous Effects of the Invention

The multilayer coated multicolor yarn according to the present inventionis parti-colored, i.e., exposes various colors on the surface of theyarn, and, therefore, a fabric woven by the inventive yarn gives aunique aesthetic feeling. In addition, due to the multiple coatinglayers, the yarn has excellent abrasion resistance, mechanicalproperties, durability, thermoformability and adhesion property.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic cross-sectional view of a two-layer coatedmulticolor yarn according to one embodiment of the present invention.

FIG. 2 is a schematic cross-sectional view of a three-layer coatedmulticolor yarn according to another embodiment of the presentinvention.

FIG. 3 is a schematic diagram of a process for fabricating a multi-layercoated multicolor yarn according to an embodiment of the presentinvention.

FIGS. 4A to 4C are schematic diagrams of apparatus for fabricating amultilayer coated multicolor yarn according to various embodiments ofthe present invention.

FIGS. 5 and 6 are schematic side views of multilayer coated multicoloryarns fabricated according to various embodiments of the presentinvention.

FIG. 7 is a photograph showing the appearance of different multilayercoated multicolor yarns produced according to various embodiments of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, the present invention will be described in detail withreference to the accompanying drawings.

FIG. 1 is a schematic cross-sectional view of a two-layer coatedmulticolor yarn according to one embodiment of the present invention.The two-layer coated multicolor yarn comprises a core yarn 1, a firstcoating layer 10 formed on the core yarn 1, and a second coating layer20 formed on the first coating layer 10. The color of the first coatinglayer 10 is exposed at a part 11 which is not covered by the secondcoating layer.20.

FIG. 2 shows a three-layer coated multicolor yarn according to anotherembodiment, which further comprises a third coating layer 30. Thethree-layer coated multicolor yarn comprises a core yarn 1, a firstcoating layer 10 and a second coating layer 20, wherein at least a part11 of the first coating layer 10 is not covered by the second coatinglayer 20 and the third coating layer 30, and at least a part 21 of thesecond coating layer 20 is not covered by the third coating layer.Thereby, each color of the first, the second and the third coatinglayers can be observed at the surface of the coated yarn.

According to the present invention, it is possible to form a desirednumber of coating layer without limitation. That is, an additional layercan be formed on the third coating layer 30 such that each color of eachlayer can appears at the surface of the coated yarn.

FIG. 1 and FIG. 2 are schematic cross-sectional views showing asimplified structure of a multi-layered multicolor yarn according to thepresent invention. In practice, each coating layer can be randomlyexposed and covered.

FIG. 3 shows a manufacturing process of a multilayer coated multicoloryarn according to one embodiment of the present invention. The processcomprises the steps of:

coating a first resin composition including a first pigment on thesurface of a core yarn and drying the first resin composition to form afirst coating layer on the core yarn;

coating a second resin composition including a second pigment on thefirst coating layer to form the second coating layer;

removing a part of the second coating layer so that the first coatinglayer is partially exposed to the outside (R); and

drying the second coating layer.

FIG. 3 shows an example of a two-layer coating as an example, but notlimited thereto. In the case of a three-layer coating, the steps offorming a third coating layer after the second coating layer is dried, aremoving a part of the third coating layer, and drying the third coatinglayer may be further performed.

That is, the method for preparing a three-layer coated multicolor yarnmay further comprise the steps of coating a third resin compositionincluding a third pigment after drying the second resin composition toform a third coating layer; removing a part of the third coating layerso that the first and second coating layers are partially exposed to theoutside; and drying the third coating layer.

In the case of a multilayer coating having four or more layers, theprocess can be repeated with the same principle.

According to a preferred embodiment of the present invention, the stepof removing (R) a part of a coating layer is performed by scraping off apart of the coating layer before drying.

In the process of scraping off a part of the coating layer, the coatingprocess may be followed by a process of scraping off a part of thecoating layer using a separate scraper.

Otherwise, as shown in FIGS. 4A to 4C, the coated yarn discharging froma coater is brought into contact with an edge of the coater outlet at apredetermined angle by using a roller.

According to one embodiment, the roller 41 a may be positioned at anangle to the coater outlet, as shown in FIG. 4A, so that the coatinglayer of the coated yarn can be scratched by the edge of the coateroutlet.

According to another embodiment, the roller 41 a may be an eccentricroller 42 a, and the path of the coated yarn discharged from the coateroutlet is changed so that the coated yarn discharged from the coatercomes into contact with the edge of the coater outlet edge at differentposition.

According to another embodiment, a set of rollers 43 a, 43 b, 43 c isinstalled into an apparatus 50 which is capable of rotating 360 degrees,thereby the coated yarn being contact with the entire circumference ofthe edge of the coater outlet.

FIG. 5 is a schematic side view of a two-layer coated yarn producedaccording to one embodiment. Scratches of the coating layer may appearspirally on the yarn surface. FIG. 5 shows a two-layer coated yarnwherein the exposed portion 11 of the first coating layer is spirallyuncovered by the second coating layer 20.

FIG. 6 is a schematic side view of a three-layer coating, in which eachcolors of three layers are exposed by the part of second coating layer21 spirally uncovered by the third coating layer 30 and the part of thefirst coating layer 11 spirally uncovered by both of the second andthird coating layers.

FIGS. 5 and 6 assume that the spiral scratching occurs regularly to someextent. However, in practice, the spiral shape may be random, and theexposed part of the lower layer may be also irregular.

According to one embodiment of the present invention, if the finallyformed coated yarn is twisted, the exposed part becomes denser, and morecolorful and vivid color contrast can be obtained. In addition, thestrength of the coated yarn greatly increases when twisted.

Thus, the process for fabricating the multilayer coating multicolor yarnaccording to the present invention may further comprise twisting thefinally dried coated yarn. The multi-layer coated multicolor yarn may betwisted by rotating with a rotational speed of 1,000 to 10,000 rpm,preferably 2,000 to 5,000 rpm.

In the present invention, the conventional resin composition for coatingthe core yarn can be used without limitation as long as it is generallyused for imparting color to a yarn in this field. For example, the resincomposition is a urethane based resin composition.

In addition to the resin composition for imparting color, otheradditives can be additionally added to obtain various functions. Forexample, a water-based thermosetting urethane composition for yarncoating may comprise 100 parts by weight of an aqueous thermosettingurethane resin, 1.5 to 2.5 parts by weight of a thickener, 8 to 15 partsby weight of a pigment, and 2.5 to 3.5 parts by weight of a mattingagent.

That is, an aqueous thermosetting urethane composition for coating ayarn according to the present invention is formed by mixing apredetermined amount of a thickener, a processing lubricant and apigment with a water-based thermosetting urethane resin, and coating acore yarn such as polyester or nylon yarn with the aqueous thermosettingurethane composition in a desired number of layers, i.e., single ormulti-layer.

Since the aqueous thermosetting urethane resin is water-based, there isno need for an organic solvent, and the desired viscosity can be easilycontrolled by adding a thickener while maintaining the required solidcontent.

In the present invention, the aqueous thermosetting urethane resin isselected from the group consisting of aqueous thermosetting siliconemodified urethane, aqueous thermosetting polyurethane, aqueousthermosetting polyacryl urethane or a mixture thereof. The thickeningagent is preferably polyacrylate.

A thickener is used to control the viscosity of the aqueousthermosetting urethane composition, and a predetermined amount of thethickener is added to obtain a desired thickness of the coating layer.

The thickener is preferably used in an amount of 1.5 to 2.5 parts byweight (PHR) based on 100 parts by weight of the aqueous thermosettingurethane resin. When the viscosity is higher than the above range, theresin composition may not be uniformly coated, and if it is lower thanthe above range, the viscosity may be too low to form an appropriatethickness of coating layer and the coating is not properly performed.

The processing lubricant may comprise a matting agent, a foamstabilizer, a dispersant, and a crosslinking agent.

The matting agent is preferably silica and may be added, preferably, inan amount of 2.5 to 3.5 parts by weight based on 100 parts by weight ofthe aqueous thermosetting urethane resin.

The matting agent is used for scattering incident or reflected light atthe surface of the coated yarn. For example, amorphous inorganic silicahaving an average particle diameter of 20 μm or less can be used toprovide a roughened surface to scatter incident light, thereby providinggood surface gloss.

Thus, a water-based thermosetting urethane resin composition may beprepared by mixing an aqueous thermosetting urethane resin with anappropriate amount of a thickener and a processing lubricant.

In the present invention, a foam stabilizer, a dispersant, and acrosslinking agent which can be used to prepare the inventive yarn arenot specially limited as long as they are generally used for fabricatinga coated yarn.

As shown in FIG. 3, a first aqueous thermosetting urethane compositionis supplied to the hopper and the core yarn is first coated with theaqueous thermosetting urethane composition, and then the coated yarn isdischarged through a nozzle and then dried. Then, a second aqueousthermosetting urethane composition is coated on the coated yarn as thesecondary coating, and a part of the second coating layer is removed byscraping, followed by drying, cooling, and winding to provide amultilayer coated multicolor yarn.

FIG. 7 is a photograph showing the appearances of various types ofmultilayer coated multicolor yarns produced according to the presentinvention.

In FIG. 7, (A) is an external view of a multicolor yarn having twocoating layers according to one embodiment of the present invention; (B)is a multicolor yarn produced by twisting the yarn (A) with a rotationalspeed of about 3,000 rpm; and (C) is an external view of a multicoloryarn having three layers of coating.

As shown in FIG. 7, the multilayer coated multicolor yarn according tothe present invention exposes various colors on the surface of the yarn,and, therefore, a fabric woven by the inventive yarn gives a uniqueaesthetic feeling. In addition, due to the multiple urethane coatinglayers, the yarn has excellent abrasion resistance, mechanicalproperties, durability, thermoformability and adhesion property.

What is claimed is:
 1. A multilayer coated multicolor yarn comprising acore yarn, a first coating layer formed on the core yarn and a secondcoating layer formed on the first coating layer, wherein at least a partof the first coating layer is not covered by the second coating layer sothat each colors of the first and second coating layers appear at thesurface of the multilayer coated multicolor yarn.
 2. The multilayercoated multicolor yarn of claim 1, further comprising a third coatinglayer formed on the second coating layer, at least a part of the secondcoating layer is not covered by the third coating layer and at least apart of the first coating layer not covered by the second coating layeris not covered by the third coating layer so that each colors of thefirst, the second and third coating layers appear at the surface of themultilayer coated multicolor yarn.
 3. The multilayer coated multicoloryarn of claim 2, further comprising an additional coating layer on thethird coating layer, wherein each colors of the coating layers appear atthe surface of the multilayer coated multicolor yarn.
 4. The multilayercoated multicolor yarn of claim 1, wherein the multilayer coatedmulticolor yarn color yarn is a twisted yarn twisted with a rotationalspeed of 1,000 to 10,000 rpm.
 5. A method for preparing the multilayercoated multicolor yarn of claim 1, comprising the steps of coating afirst resin composition including a first pigment on the surface of thecore yarn and drying the first resin composition to form the firstcoating layer on the core yarn; coating a second resin compositionincluding a second pigment on the first coating layer to form the secondcoating layer; removing a part of the second coating layer so that thefirst coating layer is partially exposed to the outside; and drying thesecond coating layer.
 6. The method of claim 5, further comprisingcoating a third resin composition after drying the second coating layer;removing a part of the third coating layer so that the first and secondcoating layers are partially exposed to the outside; and drying thethird coating layer.
 7. The method of claim 6, wherein a part of thesecond coating layer or the third coating layer is removed by scraping apart of the second or third coating layer before drying the second orthird coating layer.
 8. The method of claim 7, wherein a part of thecoating layer is scraped by making a coated yarn discharging from anoutlet of a coater contact with an edge of the coater outlet at apredetermined angle by using a roller.
 9. The method of claim 8, whereinthe roller is an eccentric roller and the coated yarn contacts with theedge of the coater outlet at different points.
 10. The method of claim8, wherein the roller is mounted on a rotatable means which is rotatableat 360 degrees with respect to the center axis of the coater outlet, thecoated yarn discharging from the coater is in contact with thecircumference of the outlet edge.
 11. The method of claim 5, furthercomprising twisting finally dried coated yarn.
 12. The method of claim6, further comprising twisting finally dried coated yarn.